![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBkO1C5PpSejAyNzPZAq_ewF04LuzPaJBQNYYi7c0HY1xDyc5D2r0ohE9sPnaoJ83Ya_Y7nNvk2TmEWoekcAlS8HF9Z3wxv6_ylim1pT8edfwDvH1gDBd2aco6F_f61BOf75HD/s320/IMG_7670.JPG)
I designed and built a custom foam removal tool that allowed me to strengthen the edges of the window openings. This tool uses four water jet cut "blades" fastened to a spindle that has an aluminum hand grip on one end. This tool really works and removes the foam core while leaving the fiberglass edge reinforcement.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5l94iKy-Xlluz_Y7bMLTKQDXSRtn_0cR0dgIcZY61TFrx-vqVU3rdLzZOGycvNESyN-omCKW0Y1nJHwt-bt_FCHOyiGSWzRe17lcN0sIjxN2CgawS4KylX6sEtMkIcj1uRmEi/s320/IMG_7667.JPG)
Since I was taking this photo with one hand, I was not able to show myself holding the aluminum support handle with my other hand. With one hand on the drill and the other supporting the end, this tool does a fine job removing foam core. This open space will later be filled with a mixture of epoxy and glass microbaloons. The edges will then be covered over with a wrap of DBM tape. Once complete, polycarbonate glazing will be fastened along these reinforced edges.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgm5O39jelkMbTrj5_quubxkJiJxfvsakVWrEUAOSS_tqUoPyL0nDVbjIYzZOvUu5k1TLHcVAskEOgFyCQxGQIYf6la4QMJ0Yin6EgAPiomhMz_cRSuyHkQF8tZvAIVnlOZiyqR/s320/IMG_7672.JPG)
here is the finished window opening after using the foam removal tool to create a 1 inch a deep foam free edge.
1 comments:
great idea!
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